Professional Documents
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2. Testing of Materials
2.1 Testing Terminology
2.1.1 Explain tensile and compression testing of metals with particular regard to
determining by calculation:
a. Ultimate tensile stress - is the maximum resistance to fracture. It is
equivalent to the maximum load that can be carried by one square inch of
cross-sectional area when the load is applied as simple tension. It is
expressed in pounds per square inch: UTS = maximum load divided by
area of original cross section
b. Yield point - The yield point, determined by the divider method, involves an
observer with a pair of dividers watching for visible elongation between
two gage marks on the specimen. When visible stretch occurs, the load at
that instant is recorded, and the stress corresponding to that load is
calculated.
c. Percentage elongation is calculated as the change in length divided by
the original length.
d. Youngs Modulus of elasticity - Young's Modulus (sometimes referred to
as Modulus of Elasticity, meaning "measure" of elasticity). It is the ratio
of stress to strain (the measure of resistance to elastic deformation).
To calculate Young's Modulus, stress (at any point) below the proportional
limit is divided by corresponding strain. It can also be calculated as
the slope of the straight-line portion of the stress-strain curve.
2.1.2 Calculate the tensile strength of a material under test from given data:
Ultimate Tensile Strength = Max Load divided by the area of the original cross
section area.
2.2.5 Identify on the Rockwell Scale the notation for hard and soft material and
how the Rockwell number is determined for a specimen under test.
For hard steels, the hardness is read on the C scale. When this reading is
recorded, the letter C must precede the number indicated by the pointer. If the
metal is softer than C-20, the B-scale setup is used, and the hardness is read on
the B scale.
2.3 Strength versus Hardness
The relationship between tensile strength and hardness is directly related.
Oil provides the slowest quench and brine the most rapid. Hardening
increases the hardness and strength of the steel but makes it less ductile.
b. Hardening Precautions
c. Tempering
d. Annealing
e. Normalizing
Produces a hard, wear resistant surface or case over a strong, tough core.
Ideal for parts which require a wear resistant surface and at the same time
must be tough enough internally to withstand the applied loads.
Steels best suited to casehardening are the low carbon and low alloy
steels. If high carbon steels are casehardened, the hardness penetrates
the core and causes brittleness.
In casehardening, the surface of the metal is changed chemically by
introducing a high carbide or nitride content. The core is unaffected
chemically. When heat treated, the surface responds to hardening while
the core toughens
Common forms of casehardening are carburizing and nitriding.
Carburizing In this process, carbon is added to the surface of low carbon
steel. Thus, a carburized steel has a high carbon surface and a lowcarbon interior.
Nitriding is unlike other processes in that, before Nitriding, the part is
heat treated to produce definite physical properties. Thus, parts are
hardened and tempered before being nitrided. Most steels can be nitrided,
but special alloys are required for best results. These special alloys
contain aluminum as one of the alloying elements and are called
nitroalloys. Nitriding can be accomplished with a minimum of distortion.
g. Parkerizing a process in which a steel part is covered with a hard oxide film
that prevents the oxygen from reaching the metal. The oxide film is formed by
soaking the steel in a solution of phosphoric acid and manganese or zinc dioxide.
h. Behaviour of Steel during heating and cooling
Changing the internal structure of a ferrous metal is accomplished by
heating to a temperature above its critical point, holding at that temperature for a
time sufficient to permit certain internal changes to occur, and then cooling to
atmospheric temperature under predetermined, controlled conditions.
i. Heating and Soaking
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e. Toughening -
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7. Identification of Materials
7.1 Classification of Steels
7.1.1 SAE Classification of Alloy Steels
Alloy Steels
a
b
c
d
e
f
g
h
i
j
K
l
Carbon
Plain carbon
Free Cutting
Manganese
Nickel
Nickel chromium
Molybdenum
Chrome molybdenum
Nickel, chrome, molybdenum
Chromium
Chrome vanadium
Silicon manganese
SAE Designation
1XXX
10XX
11XX
13XX
2XXX
3XXX
40XX
41XX
43XX
5XXX
6XXX
9XXX
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7.1.3 SAE stands for Society of Automotive Engineers and the SAE code is
used to identify the chemical composition of the structural steels.
7.2 Identification of Aluminium and Al alloys
7.2.1 Wrought Aluminium
High degree of resistance to corrosion.
Easily formed into intricate shapes
Relatively low in strength.
Most widely used in A/C construction, being used for stringers,
bulkheads, skin, rivets and extruded sections.
Cast Aluminium
These are suitable for casting in sand, permanent mold, or die
castings.
7.2.2 Difference between heat treatable and non-heat treatable Al alloy.
Non Heat treatable alloy The strength of these alloys is initially produced
by alloying the aluminum with additions of other elements. These alloys consist
of the pure aluminum alloys (1xxx series), manganese alloys (3xxx series),
silicon alloys (4xxx series) and magnesium alloys (5xxx series). A further
increase in strength of these alloys is obtained through various degrees of cold
working or strain hardening. Cold working or strain hardening is accomplished
by rolling, drawing through dies, stretching or similar operations where area
reduction is obtained. Regulating the amount of total reduction in area of the
material controls its final properties. Material which has been subjected to a
strain-hardening temper, may also be given a final, elevated temperature
treatment called stabilizing, to ensure that the final mechanical properties do
not change over time. The letter H followed by numbers denotes the specific
condition obtained from strain hardening.
Heat Treatable Alloy The initial strength of these alloys is also produced
by the addition of alloying elements to pure aluminum. These elements include
copper (2xxx series), magnesium and silicon, which is able to form the
compound magnesium silicide (6xxx series), and zinc (7xxx series). When
present in a given alloy, singly or in various combinations, these elements exhibit
increasing solid solubility in aluminum as the temperature increases. Because of
this reaction, it is possible to produce significant additional strengthening to the
heat-treatable alloys by subjecting them to an elevated thermal treatment,
quenching, and, when applicable, precipitation heat-treatment known also as
artificial aging.
Note: Because of additions of magnesium and or copper, there are also a
number of silicon (4xxx series) alloys that are heat-treatable.
In solution heat-treatment, the material is typically heated and this causes the
alloying elements within the material to go into solid solution. Rapid quenching,
usually in water, which freezes or traps the alloying elements in solution, follows
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7.2.5 Four-digit code to identify pure Al and Al alloys with the following alloying
agents:
a.
b.
c.
d.
e.
f.
Copper 2XXX
Manganese 3XXX
Silicon 4XXX
Magnesium 5XXX
Magnesium and Silicon 6XXX
Zinc 7XXX
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c. Silicon 4XXX
Silicon lowers the metals melting temperature
This results in alloys that work well for welding and brazing.
d. Magnesium 5XXX
Possess good welding and corrosion resistant characteristics.
However if the metal is exposed to high temperatures or excessive cold
working, its susceptibility to corrosion increases.
e. Magnesium and Silicon 6XXX
The Si and Mg forms magnesium silicide, which makes the alloy heat
treatable.
Has medium strength with good forming and corrosion resistance
properties.
f. Zinc 7XXX
Are more harder and stronger due to the addition of Zinc.
Widely used forms are 7075 and 7178.
7.2.7 Correct means of identification marking Al alloy sheets.
Al alloy sheets are marked with the specification number on approximately
every square foot of the material
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-T3
= solution heat treated followed by strain hardening. Different amounts of
strain hardening are indicated by the second digit, e.g. T36 indicates that the
material has been solution heat treated and has had its thickness reduced 6% by
cold rolling.
-T4
= solution heat treated followed by natural aging at room temperature to a
stable condition.
-T5
= artificially aged only (castings only).
-T6
= Solution heat-treated and artificially aged.
-T7
= solution heat treated and then stabilized to control its growth and
distortion.
-T8
= solution heat treated, strain hardened and then artificially aged.
-T9
= solution heat treated, artificially aged and then strain hardened.
-T10 = artificially aged and then cold worked.
-W
= solution heat treated, unstable temper.
7.3.2 refer 7.3.1
7.3.3 Strain hardness or temper of Al alloys (non heat treatable alloys):
-F
-O
-H
-H1
-H2
-H3
7.3.4 The digit following the designations H1, H2 and H3 indicate the degree of
strain hardening, e.g the number 8 represents the max tensile strength while O
indicates an annealed state:
-H32
-H34
-H36
-H38
-H39
7.3.5
7.3.6 Describe the identification of clad aluminum and state what the cladding
and core material may be composed of:
7.3.7 Identify common aircraft materials by their physical characteristics.
7.3.8 Describe how a heat treatable alloy can be identified using a physical test.
Refer 7.2.8
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7.3.9 Describe the meaning of the temper designation (-W) when indicating the
material condition:
It indicates the material has been solution heat treated and quenched but not
aged.
7.4 Heat Treatment of Magnesium Alloys
7.4.1 Describe the heat treatment processes relating to Mg and its alloys
including: F, O, H24, T4, T5 and T6.
Is the worlds lightest structural metal. Silvery white in colour and weighing
only 2/3 of Al.
In pure form, it does not possess sufficient strength for structural uses, but
when alloyed with Zn, Al, and Mn, it produces an alloy having the highest
strength-to-weight ratio.
Possess good casting characteristics.
Mg alloys are subject to such treatments as annealing, quenching,
solution heat treatment, aging and stabilizing.
The solution heat treatment is used to put as much of the alloying
ingredients as possible into solid solution, resulting in high tensile strength
and maximum ductility.
Aging is applied after heat treatment where maximum hardness and yield
strength are dedired.
Mg embodies fire hazards of an unpredictable nature. It will not burn until
the melting point is reached. Mg fires can be extinguished by use of an
extinguishing powder such as powdered soapstone or graphite powder.
Mg Temper Conditions:
F
as fabricated
O
Annealed
H24 strain hardened and partially annealed.
T4
Solution heat treated.
T5
artificially aged only
T6
solution heat treated only.
7.5 Identification of Mg alloys
7.6 Titanium
7.6.1 Identification, composition and characteristics of titanium and titanium
alloys
Are light weight metals with very high strength and is a metallic element
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m. Lack of lubrication
n. Weld decay Inter-granular corrosion, usually of stainless steels or certain
nickel-base alloys that occurs as the result of sensitization in the heat-affected
zone during the welding operation.
o. Hydrogen Embrittlement results when a chemical reaction takes place which
produces hydrogen gas that is absorbed into the metal. This reduces the metals
ductility and allows the formation of cracks and stress corrosion.
p. Fatigue Stress and fatigue failure
q. Erosion of rotating componentry (as in prop or turbine compressor)
r. Inclusions
8.1.4 Describe the stresses associated with the fastening or operation of A/C
hardware and components such as: bolts, nuts, studs, rivets, pins, shafts, discs,
blades, connecting rods, gears and struts.
8.2 Identification of Failure Debris
8.2.1
8.2.2 Debris test/identification methods
8.2.3 Typical gear and bearing failures
8.2.4 Purpose of SOAP sampling programs interpretation of SOAP sample
results.
9. Corrosion
9.1 Corrosion Chemistry
9.1.1 Describe the chemistry between the various forms of corrosion found on
the A/C
Corrosion is the deterioration of the metal by chemical or electrochemical
attack and can take place internally as well as on the surface. Corrosion is simply
a process wherein metals return to a natural state. There are two types of
corrosion, chemical and electro-chemical; however both types involve two
simultaneous changes. The metal that is attacked or oxidized suffers an anodic
change, and the corrosive agent is reduced and suffers a cathodic change.
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9.1.2
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e. Organic Growths
Jet a/c use a high viscosity fuel which holds more water in suspension
than other aviation fuels
Water in fuel tanks, contains microscopic animal and plant life called
microbes. These microbes live in water and feed on the hydrocarbon fuel.
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i. Filiform Corrosion
Is a special form of oxygen concentration cell corrosion or crevice
corrosion, which occurs on metal surfaces having an organic coating
system.
It is recognized by its fine thread like lines under a polyurethane enamel
finish.
It often results when the wash primer used on a metal has not been
properly cured. A wash primer is two-part metal preparation material in
which phosphoric acid converts the surface of the metal into a phosphate
film that protects the metal from corrosion & provides good bond for paint.
This conversion process relies on moisture in the air and if there is not
enough moisture to convert all of the acid, some acid remains on the
metal. If a dense polyurethane finish is then applied, the acid becomes
trapped and reacts with the Al alloy to form corrosion.
It shows itself as a puffiness under the paint film and is first noticed around
rivet heads and along the lap joints of skins.
Treatment: strip the paint; remove the corrosion; treat the metals surface;
refinish the A/C.
j. Intergranular corrosion
Is an attack along the grain boundaries of a material.
The grain boundary and the grain center can react with each other as
anode and cathode when in contact with an electrolyte.
Spot or seam welding through localized heating, can also cause grain
enlargement that leaves the metal susceptible to Intergranular corrosion.
Difficult to detect without ultrasonic or eddy current equipment.
Remedy for Intergranular carrion is replacement of the part.
k. Exfoliation Corrosion
Is an extreme case of Intergranular corrosion.
It occurs chiefly in extruded materials, such as channels or angles, where
the grain structure is more laminar than in rolled sheets or castings.
This type of corrosion occurs along the grain boundaries and causes the
metal to delaminate.
Remedy is to replace the part.
l. Stress Corrosion
Occurs when the metal is subjected to a tensile stress in the presence of a
corrosive environment.
The stresses in the metal can come from improper quenching after heat
treatment, or from an interference fit of a fastener.
Can be transgranular or Intergranular in nature.
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To prevent stress corrosion in some heat treated Al alloy parts is to shotpeen the surface to provide a uniform compressive stress on the surface.
Common locations for stress corrosion are between rivets in a stressed
skin, around pressed-in bushings, and tapered pipe fittings.
Dye penetrant inspection is required to find the actual extent of the crack.
n. Fretting Corrosion
When two surfaces fit tightly together but can move relative to one
another, corrosion occurs.
This type of corrosion is the result of the abrasive wear caused by the two
surfaces rubbing (fretting) against each other.
This rubbing prevents the formation of the protective oxide film, exposing
active metal to the atmosphere.
By the time this type of corrosion makes it appearance on the surface, the
damage is usually done and the parts must be replaced.
If the contact areas are small and sharp, deep grooves resembling brinell
markings or pressure indentations are can be worn in the rubbing surface.
As a result, this type of corrosion is called false brinelling.
Fretting corrosion occurs around rivets in a skin and is known as smoking
rivets. Rivets showing this kind of fretting must be drilled out and
replaced.
9.4.2 Describe the general identifying characteristics of corrosion on the following
metals.
a. Steel reddish rust.
b. Copper greenish film.
c. Aluminium appears as surface pitting and etching, often combined with
grey or white powdery deposits.
d. Brass
e. Magnesium appears as surface pitting and etching, often combined with
grey or white powdery deposits.
f. Titanium
g. Lead
9.5 Contributory Factors
9.5.1 Describe how the following factors contribute to corrosion.
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a. Size and type of metal thick structural sections are more susceptible to
corrosive attack than thin sections.
b. Foreign Materials soil, oil, grease, salt water, battery spills. It is important
that the a/c be kept clean.
c. Fluids and abrasives
d. Electrical potential difference
e. Lack of cleanliness refer (b) above.
f. Stress
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protect welded steel tubes mounts from internal corrosion the tubing
should be periodically filled with hot linseed oil or other type of tubing oil.
n. Control cables if carbon steel cable is left unprotected and water is
allowed to get between the cable strands, the cable will start to corrode.
The corrosion that forms on the inside of the cable is difficult to detect.
o. Welded areas Al torch welding requires the use of a flux to exclude
oxygen from the weld. These flux contain chemicals that are extremely
corrosive to Al and all traces of the flux must be removed after welding is
completed.
p. Electronic equipment circuit boards are typically protected by sealing the
wiring and circuit boards with a transparent film which excludes oxygen
and moisture from the air.
9.8 Corrosion effects on specific materials.
9.8.1 Describe specific corrosion problems relating to:
a. Ferrous metal components atmospheric oxidation of the steel, which results
in rust.
b. Al and Al alloys three forms of attack on Al alloys are particularly serious:
1. the penetrating pit type corrosion.
2. stress corrosion-cracking of materials under sustained stress.
3. Intergranular corrosion of certain improperly heat treated Al alloys.
c. Magnesium is the most chemically active of the metals used in the a/c
construction and is, therefore the most difficult to protect. Mg attack is probably
the easiest type of corrosion to detect in the early stages since Mg corrosion
products occupy several times the volume of the original Mg metal destroyed.
The beginning of the attack shows as a lifting of the paint films and white spots
on the Mg surface, and these rapidly develop into snow-like moulds or even
white whiskers.
d. Copper
e. Titanium and Ti alloys attack on Ti is generally difficult to detect. Ti, by nature
is highly corrosion resistant, but it may show deterioration by the presence of salt
deposits and metal impurities particularly at high temperatures. If Ti surfaces
require cleaning, hand polishing with Al polish or a mild abrasive is permissible.
9.9 Anti Corrosion treatments
9.9.1 Describe the following treatments relating to Al alloys
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After all the corrosion has been removed, any rough edges caused by pitting
must be faired with a fine stone or a 400 grit abrasive paper. The surface should
then be primed as soon as possible. A dry, clean surface is ideal for corrosion.
Zinc chromate primer is used to protect most freshly cleaned stainless steel
surfaces.
d/e. Nickel or chrome plating one way to protect ferrous metals is through
chrome plating. This plating produces an airtight coating over the surface that
excludes moisture from the base metal. There are 2 types of chrome plating used
on the a/c: decorative and hard chrome.
Decorative chrome is used primarily for its appearance and surface protection.
Hard chrome is used to form wear resistant surface on piston rods, cylinder
walls, and other parts subject to abrasion.
f/g. Cadmium plating almost all steel a/c hardware is cadmium plated. It
provides an attractive finish and protects against corrosion. When the Cd plating
on a part is scratched through to the steel, galvanic action takes place and Cd
corrodes. The oxides that form on the surface of Cd are similar to those on the Al
surface (dense, air and water tight). This means that no further corrosion takes
place once the initial film has formed. This type of protection is known as
sacrificial corrosion.
h. Galvanizing steel parts e.g. firewalls are typically treated with a coating of
zinc in a process called galvanizing (sacrificial corrosion protection). Zinc will
corrode and form an airtight oxide film.
i. Metal Spraying a/c engine cylinders are sometimes protected from corrosion
by spraying molten Al on their surface. To accomplish this process, a steel
cylinder barrel is sand-blasted absolutely clean, then Al wire is fed to into an
acetylene flame where the wire is melted and blown onto the surface by highpressure compressed air. (sacrificial corrosion protection).
j. Organic Coatings most common organic coating used to protect ferrous metal
is paint. However, like Al the surface must be properly prepared to ensure a good
bond. Parts which have been cadmium plated must normally have their surface
etched with a 5% solution of chromic acid before the primer adheres. After
surface preparation, a thin, wet coat of zinc chromate primer is sprayed on and
allowed to dry.
k. Zinc Chromate priming refer 9.9.1 (f)
l. Sherardizing
m. Parkerized chemically treated to provide iron and steel with dark corrosionresistant protective coating by boiling in solution of phosphoric acid and
manganese or zinc dioxide and subsequently applying coating of paraffin oil.
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Anodizing Mg with Dow # 17 produces a hard, surface oxide film which serves as
a good base for further protection by a coat of paint.
f. Dichromate conversion
g.Stannate immersion
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e. Apply developer after excess penetrant is removed and, where required, the
surface is dried. Apply the developer in a thin uniform layer over the surface to be
inspected. Developer acts like a blotter to assist the natural capillary action
bleed-out of the penetrant from discontinuities. After the developer is applied,
allow sufficient time for the penetrant to be drawn out of any discontinuities.
f. Black light (UV) operation and its advantages: UV light increases the visibility of
the defect.
g. Inspection area After the penetrant has sufficiently developed, visually
inspect the surface for indications from discontinuities.
h. Indications the developer will dry white, and if there is any dye trapped in a
crack the developer will pull it out, staining the developer red. Any red areas in
the white developer will indicate a crack or defect.
i. Post Inspection Cleaning - Remove inspection material residues from parts
after completion of penetrant inspection. This residue could interfere with
subsequent part processing, or if left on some alloys, it could increase their
susceptibility to hydrogen embrittlement, Intergranular corrosion, and stress
corrosion during service.
j. Factors affecting the success of Liquid Penetrant Inspection
the surfaces should be clean, and not too rough.
All excessdye should be removed before the developer is applied.
Use extreme care not to contaminate the developer with the dye.
k. System monitoring l. Health & Safety Considerations
Avoid long exposure to the fumes.
Avoid excessive exposure of dye or developer to hands.
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sound waves that are transmitted by the air surrounding the body. Under normal
condition these sound waves propagate longitudinally from the source of
vibration and are called Longitudinal waves. A second type of wave propagation
occurs at right angles to the direction of the sound, and this type of wave
propagation occurs only in material made of tightly bonded molecules, such as
solids are called Transverse waves or Shear waves.
Ultrasonic waves used for NDI vary in frequency from 200kHz to 25MHz, and are
reflected, focused or refracted. This sound energy propagates through a solid or
liquid material with little loss in wave energy.
Two basic ultrasonic inspection techniques are employed: Pulse-Echo and
Through-Transmission.
Pulse Echo - This process uses a transducer to both transmit and receive
the ultrasonic pulse. The received ultrasonic pulses are separated by the
time it takes the sound to reach the different surfaces from which it is
reflected. The size (amplitude) of a reflection is related to the size of the
reflecting surface. The pulse-echo ultrasonic response pattern is analyzed
on the basis of signal amplitude and separation.
Through Transmission - This inspection employs two transducers, one to
generate and a second to receive the ultrasound. A defect in the sound
path between the two transducers will interrupt the sound transmission.
The magnitude (the change in the sound pulse amplitude) of the
interruption is used to evaluate test results. Through transmission
inspection is less sensitive to small defects than is pulse-echo inspection.
Fabrication of NDI Reference Standards: Every ultrasonic test unit should have
sample materials that contain unbonds equal to the sizes of the minimum
rejectable unbonds for the test parts. Information on minimum rejectable unbond
sizes for test parts should be obtained from the OEMs manuals
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flame which is used to melt the materials to be welded. A filler rod is melted into
the puddle of molten metal to reinforce the weld.
d. Electric arc welding a group of welding processes wherein coalescence is
produced by heating with an arc or arcs, with or without the application of
pressure and with or without the use of filler metal (i.e. GTAW and GMAW)
e. Electrical resistance welding Many thin sheet metal parts for aircraft,
especially stainless steel parts, are joined by one of the forms of electric
resistance welding, either spot welding or seam welding.
f. Electron Beam welding Electron beam welding uses a very high-energy
electron beam to produce deep, narrow penetration. The electron beam has a
higher energy content than a laser beam, and is also smaller. Welding has to be
performed in a vacuum, as the electron beam is absorbed by air. This
complicates the process when changing the workpiece. On the other hand, the
absence of air is good for the welding process, as there can be no reactions
between air and the metal of the weld or workpiece.
g. Plasma Arc welding The plasma welding method employs an inner plasma
gas and outer shielding gas. The plasma gas flows around a retracted centered
electrode, which is usually made of tungsten. The shielding gas flows through the
outer jet, serving the same purpose as in TIG welding. Resistor R limits the
current in the pilot arc which can be ignited also when the torch is apart from the
workpiece.
h. Thermal Spraying Thermal spraying is used for applying metallic or ceramic
layers to metals, for such purposes as producing a corrosion-resistant or wearresistant layer on low-alloy steel.
i. Laser Welding Laser light possesses several unique properties, among which
are the fact that it is parallel and highly concentrated. It can therefore be
conducted, by mirrors or glass fibers, to a welding position that is remote from
the power unit. It is also monochromatic, i.e. at a single definite wavelength,
which depends on the type of laser used.
11.2 Welding Symbols
A welding symbol on a drawing consists of:
An arrow line (1)
One or two reference lines (2)
An elementary symbol (3)
Possible supplementary symbols
Dimensions of the weld
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Corner Joint is made when two pieces of metal are brought together so
that their edges form a corner of a box or enclosure.
Lap Joint is seldom used in a/c structures when welding with
oxyacetylene, but is commonly used when spot welding.
11.3.2 Describe the depth of weld penetration that is considered desirable for
each of the welded joints.
11.3.3 Describe why the edges of metal sheets may be beveled and notched
prior to butt welding:
It is necessary to bevel the edges so that the heat from the torch can penetrate
completely through the metal.
11.4 Welding Positional Techniques
11.4.1 Techniques used while welding in different positions:
11.4.2 Desired electrode angle when advancing the weld during arc welding.
The electrode angle consists of two positions: Work angle is the angle from the
horizontal measured at right angles to the direction of welding (fig, 7-15). Travel
angle is the angle in the direction of welding.
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Describe the nature and purpose of the various gasses used in the welding
processes:
There are two classes of flux: corrosive and noncorrosive. Zinc chloride,
hydrochloric acid, and sal ammoniac are corrosive fluxes. Corrosive flux should
NEVER be used in electrical or electronic repair work. Use only rosin fluxes. Any
flux remaining in the joint corrodes the connection and creates a defective circuit.
Rosin is a noncorrosive flux and is available in paste, liquid, or powder form.
11.16.3:
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efficiently distributing the load and reducing failures caused by differential thermal
expansion.
13.2.4 13.2.7: Omit (due general stuff)
13.2.5 Methods of finishing acrylic components by sanding, buffing and polishing
Clean the plastic by washing it with plenty of water and mild soap, using a
clean, soft, grit free cloth, sponge or bare hands.
Plastics should not be rubbed with a dry cloth since this is likely to cause
scratches.
Do not attempt hand polishing or buffing until the surface is clean. A soft,
open type cotton or flannel buffing wheel is suggested.
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c. C-Stage
d. Accelerator a material that increases the rate at which chemical reactions
would otherwise occur.
e. Autoclave - a closed vessel for producing an environment of fluid pressure,
with or without heat, to an enclosed object undergoing a chemical reaction or
other operation.
f. Balanced Laminate a composite laminate in which all laminate occur in pairs
symmetric about the mid-plane (but not necessarily adjacent to each other).
g. Bi-directional fabric
h. Bleeder a nonstructural layer of material used in the manufacture of
composite assemblies to allow the escape of excess gas and resin during cure.
i. Blocking undesired cohesion or adhesion that interferes with the satisfactory
and efficient use of the material.
j. Bridging - vacuum bagging material spanning tool or part surfaces.
k. Catalyst - a substance whose presence initiates or changes the rate of a
chemical reaction, but does not itself enter into the reaction.
l. Caul Plate - a flat or contoured tool used to distribute pressure and to define a
surface for the top of the laminate during laminate consolidation or cure.
m. Core Separation
n. Core Splicing
o. Crazing fine hairline cracks.
p. Cure to develop the strength properties of an adhesive by chemical reaction.
q. Cure Stress
r. Exothermic Reaction a chemical reaction in which heat is evolved.
s. Fabric-plain, satin and twill weave
w. Finish the final treatment or coating of a surface.
x. Gel condition
y. Glass (E & S)
z. Carbon FRP
aa. Glass FRPbb. Inhibitor - a substance used to reduce the rate of a chemical or
electrochemical reaction, commonly corrosion or pickling.
cc. Kevlar (Aramid)
dd. Kevlar FRP
ee. Lamination sequence (stacking or nesting) the arrangement of ply
orientations and material components in a laminate specified with respect to
some reference direction.
ff. Lay-Up a description of the component materials, geometry, and so on of a
laminate.
gg. Matrix the continuous constituent of a composite material, which surrounds
or engulfs embedded filler or reinforcement.
hh. Micro Cracking - a crack too small to be seen with the unaided eye.
ii. Mould Release agent
jj. Peel ply a removable ply molded onto the surface of a laminate to provide a
chemically clean surface for bonding or painting after removal.
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kk. Ply orientation the acute angle (theta) including 90 between a reference
direction and the ply principal axis. The ply orientation is positive if measured
counterclockwise from the reference direction and negative if measured
clockwise.
mm. Post Cure further treatment by time or temperature, or both, of an
adhesive to modify specific properties.
nn. Pot Life period of time during which a multi-part adhesive can be used after
mixing the components.
oo. Prepreg a type of composite material in which the reinforcing fibers are
encapsulated in an uncured resin. Prepreg must be kept refrigerated to prevent
the resin curing before it is cured. Prepreg = preimpregnated fabric.
pp. Reinforced Plastic a plastic with high strength fillers imbedded in the
composition, resulting in some mechanical properties superior to those of the
base resin.
qq. Resin Content - the amount of matrix present in a composite expressed
either as percent by weight or percent by volume.
rr. Resin Richness
ss. Resin Starvation
tt. Tracer
uu. Unidirectional Fabric ww. Warp - any variation from a true or plane surface. Warp includes bow, crook,
cup, and twist, or any combination thereof.
xx. Warp Clock -
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